AU2012244079B2 - Door Operator - Google Patents

Abstract

Abstract: Embodiments of the present invention provide a chassis-less door operator drive motor assembly with an integral fixing surface for direct fixing connection with a roller door 5 drum axle or a sectional door or tilt door drive track. The operator comprises a one piece moulding or casting that has a drive motor spindle bearing support, a gear box casing with a gear box bearing support, a bearing support for an axially rotatable output drive component and the fixing surface, which provide pre-defined and aligned positions for mounting the respective components to maintain these components in 10 interworking positions relative to each other and to the fixing surface. Thus the need to adjust relative positions of the mounted components to maintain intended working interrelationships is either avoided or substantially minimised. 3781627_1 (GHMatters) P88386.AU.1 3/1012011

Description

AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION Standard Patent Applicant(s) Smart Openers Pty Ltd Invention Title: Door Operator The following statement is a full description of this invention, including the best method for performing it known to me/us: -2 DOOR OPERATOR Field of the invention This invention relates to a door operator and relates in certain embodiments to door operators for use with roller shutter doors or sectional/tilt doors. The operator has 5 applications in moving barriers such as doors generally and hereinafter the use of the term door operator is to be understood as being an operator for use with all types of barriers that need to be moved to open and close including doors such as garage doors and/or industrial doors or gates etc. Background of the invention 10 In our Australian Innovation Patent No. 2010101382 there is disclosed a door operator which can be mounted wholly within a curtain drum of a roller shutter door. One embodiment of the present invention is related to an improved version of a door operator of that type. Door operators of that type have been made from discrete individual components which are mounted to a chassis plate that forms part of the door 15 operator. Door operators of that type utilise a number of meshing gears including an output crown wheel that drives a door curtain drum wheel to enable the door curtain to be opened and closed. We have found that when the components are made of discrete individual components and assembled together on the chassis plate, the required tolerances of assembly relative to the chassis plate are critical to ensure good 20 meshing relationship of all the gears including the meshing of gears with the crown wheel. In some instances, if the relative positioning of the gears to each other is not within certain tolerances then the motor is unable to satisfactorily drive the output crown wheel due to binding or incorrect meshing of the gears. In addition, if the components are not accurately aligned, there may be operation of the operator but 25 considerable undesired forces are imparted to the gears and other components which reduces life expectancy. Over time fastenings to the chassis plate may also loosen enabling the components to move relative to each other causing problems such as increased friction, increased play and misalignment. In addition, there is an ever increasing need to miniaturise the total assembly of the door operator in size. The 30 above statements are true for operators for other barriers such as sectional/tilt doors including gates and other barrier type panels that need to be opened and closed. Summary of the invention Therefore, according to a first broad aspect of the present invention there is provided a chassis-less roller door operator drive motor assembly with an integral fixing surface 35 for direct fixing connection with a roller door drum axle; mpfm A0135588864-vl 120476915 -3 said operator comprising a one piece molding or casting that has (a) a drive motor spindle bearing support, (b) a gear box casing with a gear box bearing support, (c) a support for an axially rotatable output gear, (d) a door position sensor assembly 5 support, (e) said integral fixing surface, and (f) a support surface rotatably supporting an output drive crown wheel so said crown wheel will be driven by said output gear and rotate a curtain drum wheel, and wherein said crown wheel drive connects with said door position sensor assembly, and wherein said crown wheel is assembled with said operator; 10 the one piece molding or casting provided pre-defined and aligned positions that have mounted a drive motor spindle bearing of said drive motor thereof, mounted said gear box bearing support and gear box components therefore, mounted said support for said output gear, and mounted a door position sensor assembly, accurately maintaining their interworking mounted positions relative to one another and to said 15 fixing surface; whereby any need to make adjustment to the respective mounted positions to permit intended interworking relationship of said drive motor spindle, of gear box components of said gear box therefore, of said position sensor assembly, and said output gear, is either avoided or substantially minimised. 20 In an embodiment a clutch is connected to said one piece molding or casting and interconnected with said gear box components to permit a release of drive between said output component and said drive motor in the event of an electric power failure or other circumstance where the drive motor cannot or should not be operated. When 25 drive is released it permits a manual opening or closing of the door to which said operator will be connected. Said output drive component can be an output drive shaft or an output gear. In an embodiment, a housing for said operator is mounted directly to said one piece 30 molding or casting. In an embodiment, said fixing surface is a bore in said molding or casting having a diameter to neatly receive a roller door curtain drum axle, said bore being wholly within said molding or casting so that the internal surface of said bore is completely 35 comprised of a portion of said molding or casting. mpfm A0135812919-vl 120476915 -4 In an embodiment, the axle of the roller door curtain drum is received in said bore and wholly extends through said molding or casting. 5 According to a second broad aspect of the present invention there is provided a chassis-less roller door operator drive motor assembly with an integral fixing surface for direct fixing connection with a roller door drum axle or a sectional door; said operator comprising a one piece molding or casting that has (a) a drive motor spindle bearing support, (b) a gear box casing with a gear box bearing support, io (c) a bearing support for an axially rotatable output gear, (d) said integral fixing surface, and (e) a support surface rotatably supporting an output drive crown wheel so said crown wheel will be driven by said output gear and rotate a curtain drum wheel, and wherein said crown wheel is assembled with said operator; the one piece molding or casting provided pre-defined and aligned positions 15 that have mounted a drive motor spindle bearing of said drive motor thereof, mounted said gear box bearing support and gear box components therefore, and mounted said bearing support for said output gear, accurately maintaining their interworking mounted positions relative to one another and to said fixing surface; whereby any need to make adjustment to the respective mounted positions to 20 permit intended interworking relationship of said drive motor spindle, of gear box components of said gear box therefore, and said output gear, is either avoided or substantially minimised. The above operator can include a clutch connected to said one piece molding or 25 casting and interconnected with said gear box components to permit a release of drive between said output drive component and said drive motor in the event the drive motor cannot be operated so as to permit a manual opening or closing of a door to which said operator will be connected. 30 In an embodiment the molding has a door position sensor assembly support providing a pre-defined and aligned position to mount a door position sensor assembly in interworking relationship with said output drive component. In an embodiment said operator is a sectional door or tilt door operator and wherein 35 said integral fixing surface is for fixing connection with a drive track, said output drive component is an output drive shaft adapted to connect with a drive cog so said drive cog will be driven by said output drive shaft to cause movement of a carriage along the mpfm A0135812919-vl 120476915 -5 drive track to affect opening and closing of a door connected to the operator via the carriage. Brief description of the drawings 5 In order that the invention can be more clearly ascertained embodiments will now be referred to with reference to the accompanying drawings wherein: Figure 1 is an exploded isometric view of components of the door operator for a roller shutter door; 10 Figures 2A through to 2H are views from different angles showing the operator; Figures 3A through to 3D are views from different angles showing how geared components are assembled relative to one another; 15 Figures 4A through to 4J are views from different angles showing components of a one piece molding or casting; Figure 5 is an exploded isometric view showing how components of the gear drive train 20 (minus an output crown wheel) are positioned relative to one another; Figures 6A through to 6G are views from different angles showing an assembly of components (minus an output crown wheel); 25 Figures 7A through to 7F showing the components of Figures 6 when viewed from different angles; Figures 8A through to 8H are views from different angles showing part of a housing for said operator; 30 Figure 9 is an exploded isometric view showing components of another part of the housing of the operator; Figures 1 OA through to 10D show the another part of the operator when viewed from 35 multiple directions; mpfm A0135588864-vl 120476915 -6 Figures 11 A through to 11 F are views from different angles of a cover plate for covering some of the gear drive components in the operator and for the fixing of a door position sensor encoder; 5 Figure 12 is an exploded isometric view of one type of door position sensor encoder that can be used in the embodiment; Figures 12A through to 12F show a part of a body of the sensor encoder; and 10 Figures 13A through to 13G show another part of a body of said sensor encoder; Figure 14A through 14G show views of components of an embodiment of a door operator for a sectional or tilt door; 15 Figures 15A through 15G are views showing the arrangement of the motor gear box and sensor encoder device of the embodiment of Figures 14; Figure 16 is an exploded isometric view of components of the motor unit gear box and encoder sensor unit of the embodiment of Figures 14; and 20 Figures 17A through 17F show views of a one piece molding or casing for the embodiment shown in Figure 14. Detailed description of the drawings 25 Embodiments of the present invention provide a chassis-less door operator drive motor assembly with an integral fixing surface for direct fixing connection with a roller door drum axle or a sectional door or tilt door drive track. The operator comprises a one piece moulding or casting that has a drive motor spindle bearing support, a gear box casing with a gear box bearing support, a bearing support for an axially rotatable 30 output drive component and the fixing surface, which provide pre-defined and aligned positions for mounting the respective components to maintain these components in interworking positions relative to each other and to the fixing surface. The moulding or casting may also include a support for a door position sensor assembly to enable mounting of a door position sensor assembly aligned in an interworking relationship 35 with the other drive assembly components. Thus the need to adjust relative positions of the mounted components to maintain intended working interrelationships is either avoided or substantially minimised. mpfm A0135588864-vl 120476915 - 6A Referring now to Figures 1 through 13 there is shown an embodiment of the invention for use with roller shutter doors. The operator 1 comprises a motor 3 in the form of an electric DC motor. The direction of rotation can be reversed by reversing the polarity of mpfm A0135588864-vl 120476915 -7 the applied voltage. The use of a DC motor does not exclude use of any other motor such as an AC motor. Such motors are to be considered as alternatives. The motor 3 drives through a gear box shown generally by numeral 5 to drive rotate an 5 output gear 7 (best shown in Figure 3B) that drives a crown wheel 9 used to engage with a curtain drum wheel (not shown) that supports a door curtain about a central axle (not shown). The crown wheel 9 has fingers 11 for engaging with spokes (not shown) of the curtain drum wheel to impart a drive thereto so that the door curtain can be wound onto and off the curtain drum wheel. There is typically a curtain drum wheel 10 provided at each side of the curtain. The two curtain drum wheels rotate relative to the fixed door curtain axle in a known manner in the door operator art. The crown wheel 9 itself is generally identical to crown wheels also known in this art and therefore a detailed description of the crown wheel 9 itself and the fingers 11 and the curtain drum wheels has not been provided as it is considered they are well known. 15 The operator includes a manually operable clutch 13 that can release a drive between the electric motor 3 and the gears in the gear box 5 to permit the roller door curtain to be manually opened in the event of power failure and the consequent absence of power to drive the electric motor 3. The clutch removes any mechanical disadvantage 20 through worm drive gearing in the gear box 5 and the motor that would otherwise prevent a manual opening of the door curtain. The clutch 13 has an operator arm 15 that can be angularly swung in a ratchet manner such as by use of a pull cord (not shown) to index ratchet the clutch 13 between a drive state and a non drive state from the motor to the output gear 7. In this regard the cord is pulled once and the clutch 25 engages or disengages drive. When next pulled in the same direction the clutch disengages or engages drive. Full details of such a clutch are disclosed in our International Patent application No. PCT/AU2011/000289 and have not been repeated here to aid brevity. The whole of the subject matter therein is hereby incorporated by reference. 30 A door position sensor assembly 17 is used to detect movement of the door drum curtain so as to electrically permit a position of the door to be determined for setting the required open and close stop positions of the door curtain. The sensor assembly 17 is mounted to a door position sensor assembly support as will be described hereinafter. 35 The door positions sensor assembly can use an angular encoder type sensor with the sensor assembly configured such that the angular encoder rotates less than 360" over the full range of travel of the door, thereby enabling the position of the door to be 3781827.1 (GHMatters) P8386.AU.1 3/10/2011 determined based on the encoder angle. Other types of position sensors may also be used, for example optical sensors or microswitches. In this embodiment, the output drive component is output gear 7 which is supported for 5 rotation about a gear axle which passes into a bore 22 (best shown in Figures 4B and 41) formed in the casting 19. The output gear 7 is held in drive engagement with an intermediate gear 35 supported on the gear box to impart drive from the drive motor to the output gear 7 via the gear box. 10 The components referred to above are all assembled relative to a one piece molding or casting 19 made from a cast metal such as aluminium, or similar. Other materials such as industrial grade plastics are not excluded. The one piece molding or casting (hereinafter referred to as casting 19) has a bore 21 therethrough (not clearly shown in Figure 1 but better shown in Figures 4B and 4E) through which the axle of the roller 15 door curtain can pass. A "U"-bolt 23 clamps the casting 19 directly to the axle so that it is held thereto and cannot be rotated relative thereto. Internal surfaces of the bore 21 therefore present a fixing surface for direct fixing with a roller door drum axle. The axle, in turn, is mounted so that it is fixed and so the door curtain drum wheels rotate relative to the axle. The arrangement of a door curtain axle being fixed and door drum 20 wheels being able to rotate relative thereto is known in this art. From the above, it should be appreciated that the casting 19 provides a one piece body with a fixing surface. The casting 19 also provides a part of a drive motor spindle bearing support. The casting 19 also provides a gear box casing 43 with a gear box 25 bearing support for the intermediate gear 35. The bore 22 is positioned relative to the gear box such the gear axle of output gear 7 such that the intermediate gear 35 and output gear 7 are held in meshing engagement. The casting 19 also comprises a surface to mount the crown wheel 9 for rotation relative to the bore 21. Thus, the one piece casting 19 obviates the need to provide a traditional chassis for an operator of 30 this type where all of the components are individually mounted thereto. This will be explained further in due course. Figure 1 shows that the operator has a casing 25 comprised of two basic components being a main casing 27 for the mechanical components and a further casing 29 for 35 electrical control components to be referred to hereinafter. The further casing part 29 is fittable relative to the main casing part 27, and the main casing part 27 then fixes directly to the one piece casting 19. Thus, when the casing 25 is assembled and fitted 37816271 (GHMatters) P88366.AU.1 3110/2011 -9 relative to the casting 19, and the crown wheel 9 assembled for rotation relative to the one piece casting 19, the operator comprises a compact arrangement with one face being covered by the cover 25 and the other face covered by the crown wheel 9. The casing 25 has a central bore 31 (not clearly shown in Figure 1) that is aligned with the 5 bore 21 so that the roller door axle can pass through the central bore of the crown wheel 9, through the bore 21, and through the central bore 31. Figures 2A through 2H show the operator arrangement in assembled form. Figure 2B shows a central bearing 33 used to rotatably support the crown wheel 9 relative to the 10 body of the casting 19. It also shows the central bore 21 through which the axle of the roller door drum passes. Figures 3A through 3E show the arrangement of the gear drive components relative to the crown wheel 9 and an arrangement for mounting and driving the door position 15 sensor assembly 17. A bearing 33 is shown integrally assembled with the crown wheel 9. Figures 3B and 3E show that the output gear 7 meshes with the internal teeth on the crown wheel 9. It also shown that an intermediate gear 35 meshes with the output gear 7. The intermediate gear 35 is, in turn, supported by and directly driven from an output of the gear box 5. These figures however, do not clearly show that output gear 20 7 and intermediate gear 35 are supported relative to the casting 19. All the figures clearly show that the sensor assembly 17 has a pick-up drive gear 37 to effect rotation of components within the sensor assembly 17. This will be described further in due course. In this embodiment the sensor assembly 17 is carried by the casting 19, and the pick-up drive gear 37 meshes with the internal teeth of the crown wheel 9 at a 25 position angularly displaced relative to output gear 7. Other arrangements are also envisaged. For example, in an alternative embodiment the sensor assembly may engage with one of the gears 7, 35 instead of the crown wheel. Alternatively the position sensor assembly may be supported for engagement with the crown wheel by the casing 25 instead of the casting 19. 30 Figures 4A through 4J show the various parts of the casting 19 without any components mounted thereto. In particular, the casting 19 contains a drive motor spindle bearing support 67. In this embodiment the casting 19 also includes a part of the motor casing but this is not essential as the motor could have its own casing that is 35 mounted to the casting 19. These figures also show the central bore 21 through which the axle of the roller shutter door passes. The casting 19 includes a bearing support 41 for supporting the bearing 33 of the crown wheel. These figures also show a gear 3781827.1 (GHMatlers) P88386 AU.1 3/10/2011 -10 box casing part 43. These figures also show a foot 45 which embraces a part of the bore 21. The foot.45 contains two spaced slots 47 through which the arms of the "U" bolt 23 pass to clamp the whole of the casting 19 relative to the roller door axle. These figures also show that the casting 19 contains parts 49 in the form of extending arms to 5 enable fixing and mounting of the casing 25 to the casting 19. It should be appreciated that the casting 19 can be precision designed so the position of mounting of the. components thereto is within predefined and permitted tolerances so that when all the components are fitted thereto there will be no need, or only a 10 limited need, to make adjustment to the positions of mounting to permit correct and intended interworking relationship of the components. Thus, with precision molding techniques good interworking relationship of the components that are to be mounted thereto can be achieved. Thus, when the motor spindle is positioned with the bearing 59 seated in the bearing support 67, the drive motor can be fastened to the casting 19 15 so that the part of the motor housing on the casting 19 aligns with the part of the motor casing carried over the motor, and will be correctly aligned for fixing. Referring now to Figure 5 there is shown an exploded view of the components that are mounted to the casting 19. The components shown are primarily related to the drive 20 train for imparting drive from the motor 3 to the output gear 7. Here, it can be seen that components of the electric motor 3 comprising a motor spindle 51 that carries rotor windings 53 that are terminated to a commutator 61. The spindle 51 also carries a worm drive 57 and two end bearings 55 and 59. The motor 3 also comprises a stator casing 65 with permanent magnets fixed internally thereof. The motor with bearing 59 25 attached are assembled relative to the casting 19 by inserting the motor spindle 51 and bearing 59 through an opening in the casting 19 and into the bearing support 67. Accordingly, bearing 59 extends into the bearing support 67 and is carried thereby. The stator casing 65 will be positioned relative to the casting 19 prior to insertion of the motor spindle 51 so that the motor spindle 51 passes generally centrally through the 30 stator casing 65. A motor end-cap 69 is then fitted at the free end of the motor spindle 51 so as to receive the bearing 55 in a bearing housing part 71 therein. The motor components can then be held assembled by bolts 71 passing into appropriate apertures in the casting 19. Thus, the casting 19, stator casing 65 and motor end-cap 69 assemble the motor as a unitary structure with the casting 19. When so assembled, 35 the worm drive 57 is displaced across a tangential region of the gear box 5. Accordingly, when a worm gear 75 is fitted into the gear box casing 5, the teeth on the worm gear 75 will mesh with the teeth of the worm drive 57. Thus, as the motor 3781827_1 (GHMatters) P88366.AU.1 3/1012011 - 11 rotates, the worm gear 75 will be rotated at a slower speed having regard to the ratios of the worm drive 57 and the worm gear 75. Worm gear 75 is journaled within a bore 77 in the gear box casing 5. The worm gear 75 has an axle boss 79 over which the intermediate gear 35 passes so that it can freely rotate relative thereto. The worm 5 gear 75 is held captive and in assembled relationship relative to the gear box 5 by cover plate 80. The cover plate 80 also provides the door position sensor assembly support as referred to previously. The cover plate 80 is, in turn, screw fitted to the gear box part of the casting 19 to hold it captive thereto. The cover plate 80 also includes a bearing face 83 to carry an axle boss 85 of the worm gear 75. The worm gear 75 io contains a central bore 87 through which a T-shaped drive pin 89 can pass. The T shaped drive pin 89 can reciprocate along its longitudinal axis within the bore 87. The head of T-shaped drive pin 89 engages within or can be displaced from a radially extending slot or slots 91 in the boss part 79 of the worm gear 75. Intermediate gear 35 contains a radially extending slot or slots (not shown) into which the head of the T 15 shaped drive pin 89 can locate. When the drive pin 89 is assembled relative to the intermediate gear 35 and the worm gear 75, a spring 93 in the form of a compression coil spring applies.a bias force to maintain the head of the T-shaped drive pin 89 in engagement with the slot or slots in the non-shown face of the intermediate gear 35 as shown in Figure 5. Washer and circlip shown collectively as 93 hold the T-shaped 20 drive pin 89, intermediate gear 35, and worm gear 75 in assembled drive relationship. An end cap 95 and circlip 97 hold the T-shaped drive pin 89 from sliding displacement in an outward direction relative to intermediate gear 35. Circlip 97 clips into circlip groove 99 in the boss part 79 of the worm wheel 75. Thus, when all the components are assembled, with the cover plate 79 in place and circlips 93 and 97 in place, the 25 bias of the spring 93 will hold the intermediate gear 35 in drive relationship with worm gear 75 and therefore with the motor spindle 51. Axial displacement in a direction extending outwardly of intermediate gear 35 to the right hand side of Figure 5 will displace the head of the T-shape drive pin 89 from engaging with the diametric extending slot or slots (not shown) on the end face of the intermediate gear 35. This, 30 in turn, will act like a dog clutch and release drive from the intermediate gear 35 to the motor spindle 51. In other words, any mechanical disadvantage produced by the worm drive 57 and the worm gear 75 that would inhibit rotation by manual forces applied to the door curtain to open or close the door curtain in the event of a power failure will no longer be present. This, in turn, means that if there is a power failure, then the T 35 shape drive pin 89 can be operated to effect a dog clutch movement to release that mechanical disadvantage thereby allowing the door curtain to be manually open and closed. A full disclosure of such a dog clutch arrangement is disclosed in our 3761627_1 (GHMatters) P883686AU 1 3/10/2011 - 12 aforementioned International Patent Application PCT/AU2011/000289 the contents of which are hereby incorporated in their entirety by reference. The detail has not been included herein in order to aid brevity. 5 Figure 5 also show that the casing 19 contains an axle 101 which rotatably mounts the output gear 7 thereto so there will be meshing drive engagement with the intermediate gear 35 and meshing drive engagement of output gear 7 with the crown wheel at a prescribed position. A washer and circlip component 103 holds the output gear 7 relative to the axle 101. 10 Whilst the dog clutch arrangement has been shown other forms of clutches may be utilised. Figures 6A through 6F show the above arrangement in further detail and also show the is mounting of the door position sensor assembly 17 to the cover plate 80 and in an operative position to pick-up drive from the internal teeth of the crown wheel 9 as will be described hereinafter. Figures 7A through 7F show the arrangement of Figures 6A through 6F in a slightly 20 different configuration with the door position assembly 17 removed. The clutch 13 shown in Figure 1 is actually a ratchet indexing mechanism that operates via operator arm 15 which is in the form of a crank handle. The clutch operator mechanism has a central pin which will effect a lateral movement on operation of the 25 arm 15 in a ratchet reciprocal arrangement so it will move and displace itself inwardly or outwardly, thereby pressing against the T-shaped drive pin 89 to effect a drive release between the intermediate gear 35 and the worm gear 75, and therefore a release with the motor spindle 51. 30 A detailed description of the ratchet mechanism is disclosed in our co-pending International Patent Application No. PCT/AU2011/000289 the contents of which are hereby incorporated in their entirety by reference. A detailed description has not been included herein in order to aid brevity. The ratchet clutch mechanism mounts directly to the cover plate 80 in an operative position relative thereto. 35 Referring now to Figures 8 through 10 there are shown various views of the casing 25. Figures 8 shows various parts of the main casing part 27, whilst Figures 9 and 10 show 3781827_1 (GHMatters) P88388AU 1 3/1012011 -13 the other casing part 29. Here, the casing parts are made from an industrial grade plastics or similar. It is possible to make the parts from pressed metal if required. Here, the main casing part 27 has a completely circular shape with an upper cavity part 105 for covering the mechanical components in the operator that are mounted relative 5 to the casting 19. In other words, when the main body part 27 is mounted to the casting 19, the mechanical components of the operator are provided in a space between the inner surfaces of the main body part 27 and the cavity 105 therein and the internal surfaces of the crown wheel 9. The cavity 105 is formed in a generally diametrical upper half of the cover 25. It is noted in this embodiment that the cavity 10 105 extends across the whole of the bore 21. Therefore in this embodiment the cavity 105 is slightly greater in size than if the cavity were truly diametrical on one side of the circular profile. The lower part of the casing 25 is provided with a further cavity part 107 for receipt of an electrical circuit control board 113 module and the necessary electric components. The outer diameter of the casing 25 corresponds approximately is with the outer diameter of the crown wheel 9 and is of a collective diameter that allows the operator assembly to be fitted within the curtain drum of a roller shutter curtain as explained previously. The lower cavity part 107 has a cover 109 shown in Figure 9 and 10 that covers the 20 electronic control circuit board 113 that will be housed within the cavity part 107. The cover 109 has fingers 111 for engaging in appropriate openings in the lower part of the casing 27 to enable retention of the cover 109 thereto. Figures 10 show the arrangements of these finger clips 111. The fingers 111 allow clip lock fastening and releasing of the cover 109 from the casing 25 when access may be required to the 25 electronic circuit board 113 that is carried therein. The cover 109 has cut-out parts 115 into which clear lenses or covers 117 can be inserted. These covers 117 allow light from LED or similar lights on the circuit board 113 to pass therethrough so as to illuminate an area near the operator. This provides lighting in that area when the operator is required to operate. This lightening may be on a timer and remain 30 activated after any door has opened or closed so as to enable illumination of the area for pedestrian safety. Figure 1 OD shows four banks of LED light means 119 adjacent to each of the lenses 117. The cover 109 has other cut-out portions to enable fixing of a user interface panel 3s 121. The user interface panel 121 has push buttons to enable setting of parameters and operating requirements for the control circuit board 113. These include settings for determining stop positions for the door curtain for the fully closed and fully open 3781827_1 (GHMattes) P88386.AU.1 3/10/201 i - 14 positions that may be required. The cover 109 may be made of the same material as the main casing part 27. The cover 109 may have other cutouts 123 for electronic plugs or sockets to enable 5 electrical connection to a power supply for the motor and for other electronic components. These may include connection for remote control transmitter and receiver combinations. Referring now to Figures 11 there is shown detail of the cover plate 80. The cover io plate 80 is typically made from metal sheet but it made be made from other material if required. The cover plate 80 has a lower part that has a generally circular outline to cover the gear box housing 5 so as to retain the worm gear 75 therein. It has an upper part with an elongate opening 123 that is surrounded by openings 25. The door position sensor assembly 17 is supported by and fitted to this upper part by screws 15 passing through the openings 125. The slot 123 positions a protruding part of the position sensor assembly 17 as will be described hereinafter. The cover plate 80 also includes a flared-out portion 127 to receive the axle 85 of the worm gear 75. In other words, it includes an axle part 83. This also acts as a locator for correct operational positioning of the ratchet mechanism forming part of the clutch operator. The cover 20 plate 80 also has an upstanding leg 27 to which a spring 129 can be attached to engage with the arm 15 to provide a spring bias return to the arm after it has been cranked. The spring is clearly shown in Figure 1. The cover plate 80 has openings 131 to permit fastening around the outer perimeter of the casing of the gear box 5 that forms an integral part of the casting 19. There are also further openings 133 to permit 25 fastening of the ratchet mechanism thereto. Referring now to each of Figures 12 through 13G there is shown detail of components of the door position sensor assembly 17. It should be appreciated that this position sensor assembly is only one of many possible known types that can be utilised. Here 30 it can be seen that the position sensor assembly 17 includes two main body parts 135 and 137 respectively. Body part 135 and body part 137 are typically made from industrial grade plastics but may be made from other materials such as cast metal. Body part 135 has a cavity 139 therein for receipt of a worm gear 141. It also contains a bore 143 (not shown in Figure 12 but shown in Figure 13). The bore 143 is for 35 receipt of a worm drive axle 145. Two U-shape openings 147 are provided on opposite side walls of the cavity 139 and provide axle bearing surfaces that extend in a direction mutually perpendicular to the bore 143. The worm gear 141 has a pair of axle 3781627.1 (GHMatters) P88386.AU.1 3/102011 -15 shoulders 149 that locate and seat in the bottom of the respective 'U-shaped openings 147. When the two parts 135 and 137 are assembled together the worm gear 141 and the worm drive axle 145 can be held there between in meshing engagement. The body part 137 has a pair of outwardly extending legs 149 that have the free ends 5 thereof arcuately curved to correspond to the external circumferential diameter of the axle 149 of the worm gear 141. Thus, when the worm drive 141 and worm drive axle 145 are assembled, the part 137 can be placed over part 135 to hold the worm gear 141 and the worm drive axle 145 therein with the legs 149 acting to hold the worm gear 141 for rotation. The opposite face of body 137 to the legs 149 comprises an io upstanding rib 151 that will locate neatly within the elongate opening 123 in the cover plate 80. This, in turn, will correctly locate the position sensor assembly 17 with its gear 37 for meshing with the internal teeth on the crown wheel 9. The position sensor assembly is an angular encoder position sensor that uses an Hall Effect Sensor to sense the angular position of a permanent magnet carried by the worm gear 141. 15 Figure 12 shows that a polarised disc permanent magnet 153 is fixed relative to the axle 149 of worm gear 141 so as to rotate when worm gear 141 rotates. An angular position sensor encoder 155 is mounted on a bracket 157 so that when the bracket 157 is mounted to the body 135 through screws passing into openings, the sensor 20 encoder 155 will be able to detect the angular orientation of the polarised magnet 153. In this context, the magnet 153 is polarised diametrically so that there is a north/south face on diametrically opposite sides. Thus, when the disc 153 rotates, there will be a corresponding interaction with the Hall effect sensor elements of the angular sensor encoder 155 so the angular position of the worm gear 151 can be determined. 25 Typically, the worm gear 141 is arranged to rotate less than 360 degrees for a full possible range of travel of the door curtain. The full possible range is typically greater than the range between the set open and set close positions for stopping the door travel during motor driven operation. However, if power fails, and the door is operated manually, the door may be opened and or closed within the full range of travel. The 30 angular sensor encoder 155 is therefore able to enable information of the angular position of the worm gear 141 when power is next restored. The door can then move to the originally set open and close stop positions without any door stop data resetting. Full details of this arrangement are disclosed in our Australian Certified Innovation Patent No. 2007101214. 35 It can therefore be seen that the operator described above provides a chassis-less compact operator assembly with pre-aligned positions for fixing of componentry that 3781627_1 (GHMalters) P88366.AU-1 3/10/2011 - 16 minimises or obviates need to make adjustment to the respective mounted positions to permit intended interworking relationship of the dive motor, of gear box components of said gear box therefore, of the position sensor assembly and of the output drive component. The need is either avoided completely or substantially minimised relative 5 to other known operators of this type and therefore represents a significant advance in mass assembly techniques for speed of production and maximum use of assembly personnel in this art. It also inhibits or minimises corresponding adjustments needed to be made in situ when the operator is mounted in an operative position with a roller door. 10 In addition, the arrangement provides for a very compact operator with a minimal front to back depth along the longitudinal axial length of the roller shutter door axle. Referring now to the embodiment of the door operator shown in Figures 14 through 17 is which is particularly for a sectional or tilt door, door operator drive motor assembly it can be seen that the one piece molding or casting 171 is similar to the one piece molding or casting 19 in the previous embodiment. The differences will be explained shortly. The sectional or tilt door has not been shown however, the track is comprised of an elongate track 173 in the form of an extruded metal channel 175. The metal 20 channel 175 is typically made from extruded aluminium however, it may be rolled steel. It has a generally flattened rectangular transverse cross section profile however, the exact shape is not critical. The track 173 is generally known in the art and has not been detailed here for clarity. The track 173 has fittings 177 and 179 at respective distal ends that carry respective cog wheels 181. The cog wheel at distal end fitting 25 177 has not been shown as it is not clearly visible in these views. An endless loop chain extends over the cog wheels and is received within the track 173 so that the chain is not generally exposed for contact with humans. The chain has not been shown in order to aid clarity. The chain connects with a sliding carriage 183. Thus, when the cog wheel 181 is rotated to move the chain, the carriage 183 is reciprocated 30 backwards and forwards from one end of the track 173 to the other. The carriage 183 in turn, operatively connects with the sectional or tilt door via a connection arm (not shown). As stated previously, the arrangement of the track 173 with the sliding carriage 183 is known in this art and a full description has not been provided. There are variations of track 173 and sliding carriage 183 in this art and all such variations 35 are to be considered as possibilities for use with the invention. The track 173 has a mounting plate 185 fitted thereto at one end by U-shape clamping brackets 187. A chassis-less door operator drive motor assembly 189 is fitted and fixed relative to the 3781627.1 (GHMatters) P88358.AU 1 3/1012011 - 17 mounting plate 185. The chassis-less door operator drive motor assembly 189 includes the one piece molding or casting 171 that comprises a drive motor bearing spindle support 191, a gear box casing 193 with a gear box bearing support 195, and a bearing support 197 for an axially rotatable output drive 199. The one piece molding or 5 casting 171 also includes a part of the electric drive motor housing 201. The arrangement is similar to the arrangement in the previous embodiment except that there is no bore 21 through which a central axle of a roller door shutter can pass. The fitting of the electric motor 3 and the internal gearing is similar with an intermediate gear 203 that corresponds with the intermediate gear 35 in the previous embodiment. io The intermediate gear 203 in turn, meshes with output gear 205 (which corresponds with output gear 7 in the previous embodiment). The output gear 205 is carried on an axle 207 that is carried in the bearing support 197. A similar dog clutch arrangement, to enable engagement and disengagement of intermediate gear 203, as disclosed in the previous embodiment is also included and has not been repeated in its description 15 herein in order to maintain brevity. The motor components are the same as described in the previous embodiment. Accordingly, details have not been repeated here in order to maintain brevity. Similar to the previous embodiment the casting 171 can have a support for a position sensor assembly. As described previously the position sensor assembly can be mounted for rotation with movement of the door irrespective 20 of whether the door is driven by the motor or manually operated. In this embodiment the cog 181 is driven to move the chain or under manual operation movement of the door causes movement of the chain and corresponding rotation of the cog 181 and engagement between the cog and the sensor assembly through the drive gears causes the position sensor to rotate permanently with movement of the door. The 25 sensor assembly is similar to that in the previous embodiment and accordingly has not been detailed again for this embodiment. An angular encoder position sensor assembly is set up similarly to the previous embodiment where the active sensor element (disc magnet) does not rotate more than 360 degrease for the full range of door travel. Figures 14 show that the clutch is operated via a pull-cord 209. The one 30 piece molding or casting 171 is fixed and fitted relative to the sectional door or tilt door drive track 173 by connecting with the mounting plate 185. In other words, the chassis-less door operator drive motor assembly 189 comprises all the drive motor components and gearing except for the cog wheel 181 at the end of the track 173 where the chassis-less door operator drive motor assembly 189 is fitted. Figures 15 35 clearly show that the axle 207 has a splined shaft 211 that mates firmly in drive connected mode with the cog 181. Thus, when the motor is operated to impart drive via intermediate gear 203 to the drive gear 205 and associated drive shaft 211, the cog 37816271 (GHMMOrs) P8836.AU.1 311001 1 -18 181 will be driven to move the endless chain thereby advancing or retreating the carriage 183 along the track 173. This motion, in turn, will then impart movement to the door curtain of the sectional door or tilt door to, in turn, permit opening and/or closing. The clutch can be operated in a similar manner to that in the previous s embodiment to disconnect the drive from the motor to the door, affected by disengaging the drive connection through intermediate gear 203 by operation of the clutch, thereby enabling the door to be opened manually in the event of a power failure. During this operation, the encoder sensor will continue to sense the angular position and thus the position of the door. Thus, when power is restored, and the io clutch re-engaged, there will be no need to reset any datum's concerning the open and close stop positions. In the embodiment shown the position sensor assembly is mounted axially with the drive shaft 211, however, alternative arrangement are envisaged, for example mounting the position sensor assembly in meshing engagement with the drive gear or intermediate gear. 15 In the example shown, the chassis-less door operator drive motor assembly 189 contains three upstanding hexagonal shaped bosses 213. This is best shown in Figure 15B. The bosses 213 are extensions of the one piece molding or casting 171 as they are screw fitted thereto and held thereto in a ridged manner. Typically, the fixing is by 20 the screws that fasten cover plate of the gear box to the one piece molding or casting 171. The free end of the bosses shown in Figures 15 are, in turn, then fitted to the mounting plate 185 by a suitable fasteners, such as screws, (not shown). The mounting plate 25 185 should be contrasted from a chassis that may have been used in operators for sectional/tilt doors in the past as the individual drive motor components are not fitted directly to this mounting plate 185 but rather to the one piece molding or casting 171. Accordingly, the advantages outlined for the previous embodiment apply to the current embodiment. The mounting plate can therefore be considered as an extension to the 30 track 173. It should also be appreciated, that whilst bosses 213 have been shown as a means to mount the one piece molding or casting 171 and the corresponding chassis-less door operator drive motor assembly 189 to the track 173, other mounting fixing may 35 comprise molding mounting components integrally in the one piece molding or casting 171. The arrangement disclosed for this embodiment minimises the use of the material for the one piece molding or casting 171 relative to if there were integral 3781627.1 (GHMatters) P88386.AU.1 3/1012011 - 19 means formed to permit mounting and fastening to the mounting plate 185 or indeed, directly to the track 173. The electric circuit board for use with this operator may be mounted to the mounting plate 185. A casing (not shown) can be mounted to the mounting plate 185 or directly to the operator assembly 189. 5 It should also be appreciated that the feature of any one or more of our prior patent applications may be incorporated in the technology herein. Details of these patent applications may be ascertained by conducting a search of the IP Australia database records under our name. The whole of the subject matter of those patent applications io is incorporated herein in their entirety by reference. It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country. 15 In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to 20 preclude the presence or addition of further features in various embodiments of the invention. Modifications may be made to the invention as would be apparent to persons skilled in the art of producing door operator devices. These and other modifications are deemed 25 to within scope of the invention the nature of which is to be determined from the forgoing description. 37816271 (GHM8tters) P8835O.AU.1 3/10/2011

Claims (14)

1. A chassis-less roller door operator drive motor assembly with an integral fixing surface for direct fixing connection with a roller door drum axle; 5 said operator comprising a one piece molding or casting that has (a) a drive motor spindle bearing support, (b) a gear box casing with a gear box bearing support, (c) a bearing support for an axially rotatable output gear, (d) a door position sensor assembly support, (e) said integral fixing surface, and (f) a support surface rotatably supporting an output drive crown wheel so said crown wheel will be driven by said 10 output gear and rotate a curtain drum wheel, and wherein said crown wheel drive connects with said door position sensor assembly, and wherein said crown wheel is assembled with said operator; the one piece molding or casting provided pre-defined and aligned positions that have mounted a drive motor spindle bearing of said drive motor thereof, mounted is said gear box bearing support and gear box components therefore, mounted said bearing support for said output gear, and mounted a door position sensor assembly, accurately maintaining their interworking mounted positions relative to one another and to said fixing surface; whereby any need to make adjustment to the respective mounted positions to 20 permit intended interworking relationship of said drive motor spindle, of gear box components of said gear box therefore, of said position sensor assembly, and said output gear, is either avoided or substantially minimised.

2. An assembly as claimed in claim 1, including a clutch connected to said one 25 piece molding or casting and interconnected with said gear box components to permit a release of drive between said output gear and said drive motor in the event the drive motor cannot be operated so as to permit a manual opening or closing of a door to which said operator will be connected. 30

3. An assembly as claimed in claim 1 or 2, wherein a casing for said operator is mounted directly to said one piece molding or casting.

4. An assembly as claimed in claim 3, wherein said casing encloses said features (a) to (e), said door position sensor assembly and said clutch, and has a shape to 35 enable fitting inside a curtain drum of a roller shutter curtain. mpfm A0135812919-vl 120476915 - 21 5. An assembly as claimed in claim 4, wherein features (a) to (e), said door position sensor assembly and said clutch are enclosed in a generally half circular part that lies predominately on one diametric side of a full circle centred about a centre of a roller door drum axle to which the operator is to be attached.

5

6. An assembly as claimed in claim 5, wherein an electric control board for said operator is housed in a part of said casing on the opposite diametric side of said full circle. 10

7. An assembly as claimed in any one of the preceding claims, wherein features (a) to (e), said door position sensor assembly, and said clutch are enclosed between said casing and said crown wheel.

8. An assembly as claimed in any one of the preceding claims, wherein said fixing 15 surface is a bore in said molding or casting of a diameter to neatly receive a roller door curtain drum axle, said bore being wholly within said molding or casting so that the internal surface of said bore is completely comprised of a portion of said molding or casting. 20

9. An assembly as claimed in any one of the preceding claims, wherein said roller door curtain drum axle is fixable to said assembly by a 'U' bolt that embraces said bore and fixingly clamps said assembly and said roller door curtain drum axle.

10. An assembly as claimed in any one of the preceding claims, wherein said one 25 piece molding or casting comprises a part of a housing of said drive motor so when said motor spindle bearing is mounted in said drive motor spindle bearing support with said motor spindle in said bearing, said drive motor can be fastened to said part of said drive motor thereby providing a casing for said drive motor. 30

11. A chassis-less roller door operator drive motor assembly with an integral fixing surface for direct fixing connection with a roller door drum axle; said operator comprising a one piece molding or casting that has (a) a drive motor spindle bearing support, (b) a gear box casing with a gear box bearing support, (c) a bearing support for an axially rotatable output gear, (d) said integral fixing surface, 35 and (e) a support surface rotatably supporting an output drive crown wheel so said crown wheel will be driven by said output gear and rotate a curtain drum wheel, and wherein said crown wheel is assembled with said operator; mpfm A0135588864-vl 120476915 - 22 the one piece molding or casting provided pre-defined and aligned positions that have mounted a drive motor spindle bearing of said drive motor thereof, mounted said gear box bearing support and gear box components therefore, and mounted said bearing support for said output gear, accurately maintaining their interworking mounted 5 positions relative to one another and to said fixing surface; whereby any need to make adjustment to the respective mounted positions to permit intended interworking relationship of said drive motor spindle, of gear box components of said gear box therefore, and said output gear, is either avoided or substantially minimised. 10

12. An assembly as claimed in claim 11, including a clutch connected to said one piece molding or casting and interconnected with said gear box components to permit a release of drive between said output gear and said drive motor in the event the drive motor cannot be operated so as to permit a manual opening or closing of a door to 15 which said operator will be connected.

13. An assembly as claimed in claim 12 wherein the molding has a door position sensor assembly support providing a pre-defined and aligned position to mount a door position sensor assembly in interworking relationship with said output gear. 20

14. An assembly as substantially herein described with reference to the accompanying drawings. mpfm A0135812919-vl 120476915